Process and apparatus for making disposable absorbent articles

ABSTRACT

A process and apparatus for controllably registering two continuously moving layers of material is provided. A continuously moving first layer has a plurality of components thereon, and a continuously moving second layer has a plurality of reference marks representing a respective plurality of components thereon. The process and apparatus control the distance between reference marks of the second layer to a selected distance, and controllably registers each reference mark of the second layer to a respective component or reference mark of the continuously moving first layer.

BACKGROUND OF THE INVENTION

[0001] The present invention generally relates to a process and apparatus for making articles, and particularly to a process and apparatus for making disposable absorbent articles.

[0002] Various products are fabricated in a continuous production line by the sequential addition of components to previously supplied components. This is particularly advantageous when one or more of the components can be supplied in the form of a single continuous layer. For example, in the formation of disposable absorbent articles, such as training pants, diapers, incontinence articles, feminine care products, or the like, a layer is normally supplied at a point in the fabrication line in the form of a continuous roll, and absorbent pads, waist elastic bands, leg elastic bands, stretchable side panels, and/or other components can be supplied at different points in the fabrication line as discrete elements.

[0003] Various processes and apparatus are available for bringing the components of a single product together so that the components in the composite product are in a desired relation with respect to each other. In bringing these components properly together, various known processes and apparatus are used to note the position of a particular component, and then to adjust the placement of subsequent components in order to properly position them.

[0004] A problem encountered with these methods and apparatus is that they do not adequately compensate for a material to be registered, for example a continuously moving layer of material, having a repeat length greater than the machine product repeat length. Consequently, during the manufacturing process, when a material having a uniform repeat length greater than a machine product repeat length is fed through the apparatus to be registered with a material having a shorter length corresponding to the machine product repeat length, the excess material uncontrollably slacks and thus results in machine wrap-ups.

SUMMARY OF THE INVENTION

[0005] In response to the discussed difficulties and problems encountered in the prior art, a new process and apparatus for making a disposable absorbent article, and in particular one having a registered graphic, has been discovered.

[0006] The present invention will be described herein in the context of registering and controlling the registration of a continuously moving second layer of material with respect to a continuously moving first layer in the manufacture of disposable absorbent articles or products, such as a child's training pant. Examples of other disposable absorbent articles include, but are not limited to, diapers, feminine care products, incontinence products, or the like. The terms “registered,” “registering” and “registration” refer to aligning objects with respect to one another, or adjusting the alignment of objects with respect to one another to achieve proper alignment.

[0007] The present invention can provide, by way of example, a child's disposable training pant having one or more appearance-related and/or functional components registered with other components.

[0008] The training pant described herein, by way of example, comprises an absorbent pad positioned between a liquid impermeable outer cover and a liquid permeable liner. The training pant further includes elastic side panels which are joined to the outer cover in order to provide elasticity thereto. The liquid impermeable outer cover can comprise two layers of material suitably joined together, in which the innermost layer can be a liquid impermeable layer and the outermost layer can be a nonwoven layer having cloth-like texture. The outermost layer has a graphic printed in registration thereon. The registered graphic generally includes a visually pleasing design or pattern and is controllably registered at a designated area in the product.

[0009] Described herein is a distinctive process and apparatus for registering a plurality of distinct and separate components on a continuously moving first layer of material with a respective plurality of distinct and separate components on a continuously moving second layer of material. The second layer of material has the components suitably represented by respective reference marks, both provided thereon at a uniform repeat length equal to or longer than a machine product repeat length. The distance between two successive reference marks is determined and compared to a selected distance. The second layer of material is then controllably microcreped or micropleated so that the distance between two successive reference marks substantially equals the selected distance. The second layer is then controllably registered to the first layer of material so that each reference mark on the second layer is selectively registered with a respective component or reference mark on the first layer.

[0010] The amount of microcreping or micropleating can be controllably adjusted by, for example, varying the speed at which the second layer moves, the speed of the vacuum conveyor belt over which the second layer moves and/or varying a pressure applied to the second layer as it moves along the vacuum conveyor belt.

[0011] The second layer has the reference marks selectively provided thereon to correspond to a respective plurality of distinct and separate components, such as graphics. A first sensor generates a signal in response to each reference mark. The distance between each newly generated signal and the most recently preceding signal is suitably measured in units of a driving mechanism, so that the speed of the driving mechanism can be selectively controlled to adjust the speed and/or tension of the second layer to controllably microcrepe or micropleat the second layer, such that the distance between a subsequent newly generated signal and its most recently preceding signal is one machine product repeat length. Thus, the repeat loop refers to repeatedly duplicating a product length between two successive reference marks by accurately measuring their current distance apart and calculating a desired speed reference for a main drive control system.

[0012] In one embodiment of this invention, the second layer of material desirably is a continuous polyethylene film preprinted with a plurality of separate and distinct graphics. In other embodiments of this invention, the second layer may be any suitable material, for example a nonwoven web material, a composite structure including a nonwoven web material and a film, such as a polyethylene film, a coated nonwoven web material, and an elastic assembly.

[0013] Desirably, the second layer has an initial repeating length greater than the machine product repeat length. The second layer is controllably microcreped or micropleated to a final repeating length equal to the machine product repeat length, to appropriately correspond the distance between two successive reference marks to the machine product repeat length. Once the second layer is microcreped or micropleated to the desired or proper length, i. e. the machine product repeat length, it may, if desired, be joined to another layer, such as a nonwoven, spunbond web, a polypropylene web, an absorbent assembly or another layer to substantially stabilize the second layer.

[0014] In one embodiment of this invention, the second layer can be microcreped or micropleated using a vacuum roll or conveyor that rotates or moves at a speed different from a speed at which the layer to which the second layer is attached, for example a third layer of material, moves. This differential in speed of the vacuum roll to the third layer causes the second layer to become microcreped or micropleated as the second layer is joined to the third layer. It is apparent to those skilled in the art that more than one layer can be attached to the second layer using this process. Desirably, the layers to be attached have an affinity for each other, such-as by use of adhesives or electrostatics, to pull the second layer off the vacuum roll or conveyor to prevent or reduce material wrap-ups. By supplying the second material using a vacuum roll or vacuum conveyor, the second layer which moves faster than the third layer, for, example, is attached to the third layer while maintaining control of the second layer without any slack in the material, which can create a break in the material.

[0015] The registration control of this system uses a computer, a method of sensing reference marks, such as a photoelectric device, a machine reference signal obtained through the use of a device, such as a proximity switch, programmable limit switch, or encoder marker, a counter, and other hardware and software to control repeat length and registration control. Registration control can be provided in two stages. This first stage can function independently of the second stage, but requires operator input for target placement of the graphics on the product. The second stage replaces the operator input by automatically calculating the target placement by using a system of sensors used in conjunction with computer hardware and software to inspect for registered location, repeat patterns, and set point error. The second stage of registration control is referred to as Automatic Setpoint Generation. The calculated target placement is used as a setpoint to control the above registration system which uses motor and drive to adjust the second layer speed, as necessary for desired registration. Adjustments to the second layer are made so that the preprinted graphics are desirably registered with a respective plurality of components.

[0016] These features advantageously control a layer moving at high speed in order to register it with another layer. Further, the features control an amount of uncontrolled slack or excess material and prevents or reduces “wrap-ups” as the second layer is laminated to the nonwoven, spunbond web, for example. The term “wrap-ups” refers to situations wherein the excess material of the longer repeating length layer jams in the machine, for example at the registration nips, preventing proper registration of the layers and resulting in machine shut-down. In particular, there is provided accurate, real time information during the production process, and rapid adjustments to the process to provide the desired configuration and registration of the reference marks and their associated components in the final product.

[0017] Each product length has at least one set of graphics on the continuously moving second layer. Associated with each set of graphics is a reference mark. This means that each reference mark is selectively positioned with regard to a respective set of graphics, so that the reference mark can be sensed and appropriately registered in the product, thereby properly registering each set of graphics in its product. Earlier, a reference mark was described in terms of specific examples, and in the following description the reference mark is selected as an optically brightened mark. A reference mark, whether an optically brightened mark or other reference mark, can be configured in any desired size or shape. The reference mark may comprise a generally rectangular region having a machine direction dimension of about 19 millimeters and a cross direction dimension of about 37 millimeters. Other dimensions optionally may be employed. In one embodiment of this invention, the entire graphic pattern or any portion or part of the graphic pattern, for example a highlighted waist area, can also be used as a reference mark.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The above-mentioned and other features of the present invention will become more apparent, and the invention itself will be better understood by reference to the following detailed description of the invention, taken in conjunction with the accompanying drawings wherein:

[0019]FIG. 1 illustrates a front view of one article having a registered graphic thereon;

[0020]FIG. 2 illustrates a front view of another article having a registered graphic thereon;

[0021]FIG. 2A representatively illustrates the article of FIG. 2 in a partially disassembled, stretched flat state;

[0022]FIG. 3 illustrates a continuously moving layer having a plurality of separate and distinct graphics thereon;

[0023]FIG. 4 illustrates a continuously moving composite layer having a plurality of separate and distinct graphics thereon;

[0024]FIG. 5A schematically illustrates an apparatus and process for the manufacture of an article having a registered graphic thereon;

[0025]FIG. 5B schematically illustrates an apparatus and process for the manufacture of an article having a registered graphic thereon;

[0026]FIG. 6 illustrates a schematic block diagram of the flow of data utilized in conjunction with the apparatus and processes in FIGS. 5A and 5B;

[0027]FIG. 7 illustrates a block diagram of the electronic gear box in FIG. 6; and

[0028]FIG. 8 graphically illustrates a placement control utilized in conjunction with the apparatus and processes in FIGS. 5A and 5B.

DETAILED DESCRIPTION OF THE INVENTION

[0029] The following detailed description will be made in the context of registering and controlling the registration of one continuously moving layer with respect to a second continuously moving layer in the manufacture of disposable absorbent articles, and specifically a child's training pant. Examples of other disposable absorbent articles include, but are not limited to, diapers, feminine care products, incontinence products, or the like. The present invention also contemplates other products or devices unrelated to disposable absorbent articles. For the purposes of this description, the term “product” can refer, but is not limited, to any article, device, laminate, composite, or the like. The term “component” can refer, but is not limited, to designated selected regions, such as edges, corners, sides or the like; structural members, such as elastic strips, absorbent pads, stretchable layers or panels, layers of material, or the like; or a graphic. The term “graphic” can refer, but is not limited, to any design, pattern, or the like.

[0030] A child's disposable training pant can have multiple appearance-related and/or functional components registered within selected machine direction (MD) and/or cross-machine direction (CD) ranges. The term “machine direction” refers to the primary direction of movement of continuously moving layers in the manufacturing process, and the term “cross-machine direction” refers to a direction transverse to the machine direction. The described example herein is that of registering a graphic within a designated area of the product.

[0031] Thus, the present invention can provide a child's disposable training pant having one or more appearance-related or functional components registered with other components. Examples relating to components that are appearance-related include, but are not limited to, the registration of graphics; highlighting or emphasizing leg and waist openings in order to make product shaping more evident or visible to the user; highlighting or emphasizing areas of the product to simulate functional components such as elastic leg bands, elastic waistbands, simulated “fly openings” for boys, and ruffles for girls; highlighting areas of the product to change the appearance of the size of the product; registering wetness indicators, temperature indicators, and the like in the product; registering a back label, or a front label, in the product; and registering written instructions at a desired location in the product.

[0032] Examples of functional components include, but are not limited to, waist elastics, leg elastics, areas of breath ability, fluid repellent areas, fluid gettable areas, adhesives or coatings, encapsulated inks, chemically-sensitive materials, environmentally-sensitive materials, heat-sensitive materials, moisture-sensitive materials, perfumes, odor control agents, inks, fasteners, fluid storage areas, textured or embossed areas, or the like.

[0033] The training pant described herein, by way of example, comprises an absorbent pad positioned between a liquid impermeable outer cover and a liquid permeable liner. The training pant further includes elastic side panels which are joined to the outer cover in order to provide elasticity thereto. The liquid impermeable outer cover can comprise two layers of material suitably joined together, in which the innermost layer can be a liquid impermeable layer and the outermost layer can be a nonwoven layer having cloth-like texture. The innermost liquid impermeable layer has a graphic printed in registration thereon. The registered graphic generally includes a visually pleasing design or pattern and is controllably registered at a designated area in the product. One registered graphic includes a graphic positioned on the front center of the product. This graphic is preferably circular and is about 76 millimeters in dimension, and can range in size from about 25 millimeters to about 130 millimeters. The center of the graphic is about 83 millimeters from the front edge of the waist opening. The graphic may include simulated elastic leg bands, a simulated elastic waistband, a simulated “fly opening” for boys, simulated ruffles for girls, or the like.

[0034] A more detailed description of the construction and design of the above-described training pant can be found in U.S. Pat. No. 4,940,464 issued Jul. 10, 1990 to Van Gompel et al., the disclosure of which is incorporated herein by reference.

[0035] Described herein is a distinctive process and apparatus for registering a plurality of distinct and separate components on a continuously moving first layer of material with a respective plurality of distinct and separate components on a continuously moving second layer of material. The second layer of material has the components suitably represented by respective reference marks, both provided thereon at a uniform repeat length about equal to or longer than a machine product repeat length. The distance between two successive reference marks is determined and compared to a selected distance. The second layer of material is then controllably microcreped or micropleated so that the distance between two successive reference marks substantially equals the selected distance, which in this case is one machine product repeat length; this is termed the “repeat loop.” The second layer is then controllably registered to the first layer of material so that each reference mark on the second layer is selectively registered with a respective component or reference mark on the first layer; this is termed the “placement loop.”

[0036] The amount of microcreping or micropleating can be controllably adjusted by varying the speed of the second layer. The term “reference mark” can refer, but is not limited, to structure such as waist or leg elastics, adhesive beads, corners or edges of structure, transporting mediums such as conveyor belts, visual marks, magnetic marks, electrical marks, electromagnetic marks, optical brighteners sensitive to ultraviolet radiation, or the like, all of which can be sensed, detected, or otherwise identified by an appropriate device. The term “machine product repeat length” refers to a selected distance, which in this example is the measured distance between successive, like components during manufacture. For example, between successive waist bands, absorbent pads, or the like. Or in other words, the machine product repeat length is the length of one product during the manufacturing process. Thus, when a reference mark of the second layer is registered with a reference mark of the first layer, the component represented by that reference mark of the second layer is registered with the component represented by the reference mark of the first layer.

[0037] With regard to the repeat loop, the second layer has the reference marks selectively provided thereon to correspond to a respective plurality of distinct and separate components, such as graphics. A first sensor generates a signal in response to each reference mark. Software and/or hardware filtering can be provided for the sensor to compensate for poor signal quality, or to distinguish between a multitude of signals. The distance between each newly generated signal and the most recently preceding signal is suitably measured in or converted to units of a driving mechanism, so that the speed of the driving mechanism can be selectively controlled to adjust the speed of the second layer to controllably microcrepe or micropleat the second layer, such that the distance between a subsequent newly generated signal and its most recently preceding signal is one machine product repeat length. Thus, the repeat loop refers to repeatedly duplicating a product length between two successive reference marks by comparing their determined distance apart with a selected distance.

[0038] With regard to the placement loop, a desired registration of a reference mark to a component is performed by comparing and controlling a related datum value to a target set point. A “datum value” refers to a measured distance between a reference mark and a machine-generated constant reference signal, such as a marker pulse from a proximity switch or a lineshaft or a marker pulse from a tech generator and the like. A “target set point” refers to a selected value within which the datum value is maintained.

[0039] There is described herein, by way of example, a distinctive process and apparatus for using a preprinted, microcrepable or micropleatable second layer of material including a plurality of distinct and separate graphics thereon, microcreping or micropleating the second layer to a selected length by varying the speed thereof, and then applying and registering it to a first layer that includes preassembled, preapplied components, such as absorbent pads, thereby providing a manufacturing process for individual disposable absorbent articles having graphics registered thereon at designated areas. The process and apparatus can also be used to apply, during manufacture, other various functional and appearance-related components that have been printed, joined, positioned, or the like, on a layer at a specified location so as to be selectively registered in the final product.

[0040] In one embodiment of this invention, the second layer of material desirably is a continuous polyethylene film preprinted with a plurality of separate and distinct graphics. The printed graphics are arranged such that they ultimately will be positioned at the same designated area in each finished product. The term “finished” or “final,” when used with reference to a product, means that the product has been suitably manufactured for its intended purpose. In other embodiments of this invention, the second layer may be any suitable material, for example a nonwoven web material, a composite structure including a nonwoven web material and a film, such as a polyethylene film, a coated nonwoven web material, and/or an elastic assembly.

[0041] Desirably, the second layer has an initial repeating length greater than the machine product repeat length. The second layer is controllably microcreped or micropleated to a final repeating length equal to the machine product repeat length, using speed variations, to appropriately correspond the distance between two successive reference marks to the machine product repeat length in order to register the reference marks to previously processed and preplaced components, such as, by way of example, absorbent pads. The use of the term “microcrepable” or “micropleatable” refers to that property of a material or composite material that permits it to temporarily gather without permanent set where upon removal of the gathering, the material recovers at least a portion of its original size and shape. As used throughout this description, the terms are interchangeable and will be referred to as “microcrepe,” “microcreped,” and/or “microcrepable.” The microcreping of the second layer is controlled by increasing or decreasing a speed at which the second layer is applied to a vacuum conveyor or a vacuum roll, for example, using an electronically controlled, motor driven roll. Suitable motor driven rolls include, but are not limited to, vacuum rolls, high friction rolls or static rolls. Once the second layer is microcreped to the desired or proper length, it may, if desired, be joined to another layer, for example a third layer of material such as a nonwoven, spunbond web, a polypropylene web, an absorbent assembly or another layer, to substantially stabilize the second layer, thereby maintaining its microcreped shape and/or length in order to withstand further processing in the apparatus without any substantial change in length or placement relative to other components of the second layer. A system of sensors used in conjunction with computer hardware and software inspects for registered location and repeat patterns. The data received from these sensors is used to control the motor, which adjusts the second layer's speed and/or tension as necessary for desired registration. Adjustments to the second layer are made so that the preprinted graphics are desirably registered with a respective plurality of components.

[0042] Additionally, a set point error loop can be added to work jointly with the control loop to correct any error between the target set point and the actual measurement on the product. This part of the control system is highly desirable but not required for the system to function. An operator can provide this input to the control system to correct any changes between the target set point that the control system is using to the actual product measurements being taken and inputted to the system through a human-machine interface.

[0043] In one embodiment of this invention, a driven feed roll or nip feeds the second layer of material to a vacuum conveyor (FIG. 5A) or a vacuum roll (FIG. 5B) that allows the over feed of material to gather on the conveyor. The vacuum helps take the excess material being fed from the feed roll, which feeds the second layer traveling at a higher rate of speed than the first layer and/or the third layer. This is desirable when advance phase moves are made, as described below.

[0044] In certain embodiments of this invention, a vacuum roll or vacuum conveyor carries the second layer towards a third layer of material, for example, and while still on the vacuum roll or conveyor or in close proximity thereto, the second layer contacts the third layer without wrap-ups or slack web in the second layer. Vacuum can be used to transport the second layer towards the third layer. Further, vacuum can be used to microcrepe the second layer during the contacting process. The microcreping results from the difference in feed rate of the two materials, for example the difference in feed rate of the second layer and the feed rate of the third layer. Desirably, the second layer is traveling or moving faster than the third layer and the excess material in the second layer is microcreped.

[0045] In certain embodiments of this invention, other suitable holding or transferring mechanisms, for example, electrostatic means, magnets, friction, adhesion and adhesives may be used to promote contact between the two layers of material and/or between the second layer and the vacuum conveyor roll. It is important that the slack that is due to the overfeeding is controlled through the microcreping step to prevent a wrap-up from occurring. After the second layer is laminated or joined to the first layer and/or the third layer, the material is stable and the vacuum and/or other conveying devices are not required.

[0046] These features advantageously control a layer moving at high speed in order to register it with another layer. In particular, there is provided accurate, real time information during the production process and rapid adjustments to the process to provide the desired configuration and registration of the reference marks and their associated components in the final product.

[0047] As described, a continuously moving layer may have a plurality of separate and distinct graphics thereon, and is controllably microcreped in order to register those graphics in a plurality of finished products. The use of the term “layer” can refer, but is not limited, to any type of substrate, such as a woven web, nonwoven web, films, laminates, composites, elastomeric materials or the like. A layer can be liquid and air permeable, permeable to air but impermeable to liquids, impermeable both to air and liquid or the like.

[0048] Each of the separate and distinct graphics on the continuously moving layer has a reference mark associated therewith. This means that each reference mark is selectively positioned with regard to a respective graphic, so that the reference mark can be sensed and appropriately registered in the product, thereby properly registering each graphic in its product. Earlier, a reference mark was described in terms of specific examples, and in the following description the reference mark is selected as an optically brightened mark, which can be configured in any desired size or shape. For example, the reference mark may comprise a generally rectangular region having a machine direction dimension of about 19 millimeters and a cross-machine direction dimension of about 37 millimeters. Other suitable dimensions may be employed. It is to be understood that the various detecting and sensing means described herein are to be appropriately compatible with the type of associated reference mark that is to be detected or sensed. The term “associated” refers to the reference mark either being directly on a component that it represents, such as a graphic, or being selectively spaced there from. The optically brightened mark is provided to be sensitive to ultraviolet radiation. The optical brightener is, for example, capable of absorbing ultraviolet radiation and then fluorescing to emit light spectra that can be sensed by an appropriate and compatible detector or sensor. Ultraviolet radiation is generally understood to include electromagnetic radiation having wavelengths ranging from about 20-400 nanometers. Suitable optical brighteners include, for example, UVITEX OB manufactured by Ciba-Geigy, and LEUCOPURE EGM manufactured by Sandoz Chemicals Corporation.

[0049] Where the reference mark comprises ultraviolet sensitive optical brighteners, a suitable detector or sensor is a UV activated detector, such as a SICK detector model LUT 2-6 available from SICK OPTIK ELEKTRONIK, INC., a business having offices in St. Paul, Minn., U.S.A.

[0050] Other suitable reference marks, as well as sensors, computer devices, motors, and the like are described in U.S. Pat. Nos. 5,235,515; 5,359,525; and 4,837,715; the disclosures of these three U.S. patents being incorporated herein by reference.

[0051] The described process and apparatus utilize several devices, and representative devices include an encoder, signal counters, and sensors. An encoder generates a pulse train, which is a selected number of pulses per revolution of the encoder shaft, for subsequent counting and control. A signal counter receives a generated pulse train from an encoder, and counts the pulses for subsequent query. A sensor senses an occurrence or interruption in a process and generates a signal in response thereto. In this description, the term “mechanical side” refers to structure such as a lineshaft, laminator, chill rolls, a product tacker and other similar physical structure and devices. The term “registration control side” generally refers to components not within the mechanical side, and can include items such as a motor controller, an electronic gear box, various types of processors, other related electrical devices, data processing devices, software and the like.

[0052] Referring to FIG. 1, there is illustrated a child's disposable training pant 10 generally comprising a front panel 12, a back panel 14, a crotch panel 16 interconnecting front and back panels 12, 14, and a pair of elastic side panels 18. Each elastic side panel 18 is formed from two separate elastic portions (FIG. 2A) and are suitably joined together, such as by ultrasonic bonding, to form a side seam 20. Upon the construction of side seams 20, a waist opening 22 and leg openings 24 are formed. The side seams 20 may be constructed to be manually tearable in order to allow training pant 10 to be disassembled manually by the caregiver, so that it can be easily removed from the child after a bowel movement. The elastic side panels 18 (FIG. 1) and side seams 20 can be provided in any suitable manner. One specific manner of supplying elastic side panels 18 is described in U.S. Pat. Nos. 5,224,405 and 5,104,116 issued Apr. 14, 1992, both to Pohjola, which are incorporated herein by reference. The provision of side seams 20 can be accomplished in the manner described in U.S. Pat. No. 5,046,272 issued Sep. 10, 1991 to Vogt et al., which is incorporated herein by reference.

[0053] Training pant 10 further comprises a front waist elastic 26 suitably joined to front panel 12, a back waist elastic 28 suitably joined to back panel 14, leg elastics 30 suitably joined to crotch panel 16, and an absorbent pad 32 (FIG. 4) positioned between a liquid impermeable outer cover or backsheet 34 (FIG. 1) and a liquid permeable liner or topsheet 36. The basic construction of a training pant is well known in the art, and one particular construction is that described in U.S. Pat. No. 4,940,464, issued Jul. 10, 1990 to Van Gompel et al., the disclosure of which has been incorporated herein by reference. The patent to Van Gompel et al. also describes various materials of which a training pant can be made, and the methods of constructing the training pant.

[0054] As illustrated in FIG. 1, a registered graphic 38 is selectively positioned on front panel 12, and in this illustration comprises a design of a simulated “fly opening” 23, typical of a boy's underwear, and a rainbow, sun, clouds, and cars. The registered graphic 38 can be any type of desired pattern, artistic feature, written instructions, or the like, and is desired to be positioned in the article at a selected location. Naturally, registered graphic 38 comprising a simulated fly opening 23 would be totally unacceptable from an aesthetic and/or functional viewpoint if it were located at crotch panel 16 or back panel 14.

[0055] Referring to FIG. 2, another training pant 40 is illustrated, which can be typically used for young girls. In this design, a registered graphic 42 includes simulated waist ruffles 29, simulated leg ruffles 31, a rainbow, sun, clouds, wagon and balloon. Again, any suitable design can be utilized for a training pant intended for use by young girls, so as to be aesthetically and/or functionally pleasing to them and the caregiver.

[0056] Registered graphic 38 in FIG. 1 or registered graphic 42 in FIG. 2 can be controllably registered as desired, depending upon the size and shape of the graphic and that portion of the article upon which the graphic is to be registered. In FIG. 1, graphic 38 is controllably registered within a designated area 39 which, as viewed in FIG. 1, is bounded or defined by a front waist edge 116, panel seams 21, and a crotch panel line 17. Panel seams 21 are the seams at which the respective elastic side panels 18 are suitably joined to front panel 12 and back panel 14. Again, a more specific description of the construction and manufacture of this design of a training pant 10 is contained in the aforementioned U.S. Pat. No. 4,940,464. The crotch panel line 17 is, for purposes of explanation herein, simply the line or boundary formed at the bottom of crotch panel 16 as illustrated in FIG. 1. Thus described, designated area 39 has four defined boundaries comprising front waist edge 116, panel seams 21, crotch panel line 17, and those portions of leg openings 24 extending between a respective panel seam 21 and crotch panel line 17. It is not necessary that a designated area 39 be completely defined or bounded by a closed line or closed boundary. For example, in FIG. 1, the designated area 39 could be defined by only front waist edge 116 and panel seams 21, which sufficiently define a designated area 39 in which a graphic 38 can be controllably registered. In this case, the graphic 38 can be controllably registered a selected distance from front waist edge 116, and centered between panel seams 21.

[0057] Another example of the flexibility in choosing a designated area 39 is illustrated in FIG. 2A, which illustrates the training pant 40 in FIG. 2 in a partially disassembled, stretched flat state. This can be accomplished by taking the finished training pant 40 of FIG. 2 and manually tearing seams 20 and then laying the pant 40 flat and stretching it sufficiently to remove any gathers or pleating caused by any incorporated elastic members. In FIG. 2A, designated area 39 is defined or bounded by front waist edge 116, panel seams 21, back waist edge 118, and a pair of leg opening edges 25 extending between respective panel seams 21. Thus, in FIG. 2A, designated area 39 is generally rectangular in shape, and registered graphic 42 is registered within and throughout the surface area of designated area 39. Registered graphic 42 comprises several component designs, such as simulated leg ruffles 31 and simulated waist ruffles 29. As viewed in FIG. 2A, leg opening edges 25 are linear or straight lines. However, in FIG. 2, simulated leg ruffles 31 provide a perceived curvature or shape to training pant 40, which is one of the unique features herein.

[0058] There is uniquely and advantageously provided a very close tolerance in the registration of a desired component, such as graphics 38, 42, within any selected area, such as a designated area 39. With reference to FIG. 1, it is apparent that the simulated fly opening 23 of graphic 38 needs to be registered within front panel 12. It would be undesirable to have training pant 10 manufactured by a method and/or apparatus that could not control the proper registration of simulated fly opening 23, otherwise the simulated fly opening 23 could appear at back panel 14 or crotch panel 16. The present invention provides a highly controlled registration of a desired component, such as a graphic 38 or 42, within a desired designated area, such as designated area 39, within a tolerance of about plus or minus 20 millimeters, and within a more particular tolerance between about plus or minus 10 millimeters and within an even more particular tolerance between about plus or minus 3 millimeters.

[0059] Referring now to FIG. 5A, there is schematically shown an apparatus and process for assembling in part a plurality of training pants. A supply device 44 continuously supplies a continuous, tissue-wrapped absorbent 46 to a separating device 48 that separates the continuous, tissue-wrapped absorbent 46 into a plurality of distinct and separate absorbent pads 32. The supply device 44 can be any conventional mechanism for supplying the absorbent 46. Generally, a conventional supply device 44 will include a hammermill for forming fluff fibers and, if desired, for providing an enclosure for mixing superabsorbent material with the fluff fibers, and then depositing the fluff and superabsorbent material on a forming drum having a desired absorbent design. The forming drum then deposits the shaped absorbent on a continuously moving tissue material, which is thereafter delivered to a folding board for folding the tissue about the absorbent. This provides the continuous, tissue-wrapped absorbent 46. The absorbent 46 can include any desired mixture or blend of absorbing materials, such as fluff and superabsorbent materials. Suitable superabsorbent materials are available from various commercial vendors, such as Dow Chemical Company located in Midland, Michigan, U.S.A., and Stockhausen GmbH & Co. KG, D-47805 Krefeld, Federal Republic of Germany. Typically, a superabsorbent material is capable of absorbing at least about 15 times its weight in water, and desirably is capable of absorbing more than about 25 times its weight in water. One preferred type of fluff is identified with the trade designation CR1654, available from U. S. Alliance, Childersburg, Ala., U.S.A., and is a bleached, highly absorbent sulfate wood pulp containing primarily soft wood fibers. Additional suitable materials for the absorbent 46 include those materials described in U.S. patent application Ser. No. 09/939,061, filed on Aug. 24, 2001, the disclosure of which is incorporated herein by reference.

[0060] A conveyor 50, which can be any conventional conveyor well known in the art, conveys the absorbent 46 to the separating device 48. A supply device 52 provides a continuously moving first layer of material 54, upon which can be disposed any desired component, such as the separate and distinct absorbent pads 32 formed by separating device 48. The supply device 52 can be any standard unwind mechanism that generally comprises a pair of spindles, a festoon assembly, and a dancer roll for providing first layer 54 at a desired speed and tension. One example of a standard unwind is a model MB 820, available from Martin Automatic Corporation of Rockford, Ill., U.S.A. The continuously moving first layer of material 54 can be any desired material suitable for the particular product being assembled. In this description of a training pant 10 (FIG. 1), continuously moving first layer 54 is a liquid permeable material that will subsequently form or become liquid permeable topsheet 36 (FIG. 1). Topsheet 36 can be made of any suitable materials well known in the art, and examples of suitable materials are described in the aforementioned incorporated U.S. patents.

[0061] Upon being moved or delivered to the separating device 48, the continuous, tissue-wrapped absorbent 46 is cut into the separate and distinct absorbent pads by a knife roll 56 and an anvil roll 58 comprising separating device 48. The knife roll 56 can have any desired number of blades thereon, and in this example has two blades 60 diametrically disposed thereon for forming absorbent pads 32. The knife roll 56 is driven by and mechanically coupled through gearing to anvil roll 58, which is operatively driven by a main lineshaft 128 (FIG. 6) in any suitable manner well known in the art. A constant reference means, such as a proximity switch 62, is coupled to anvil roll 58 for generating a reference signal for each cut absorbent pad 32. For purposes herein, the separating device 48 is operated at a substantially constant speed during the manufacturing process so that each reference signal generated by proximity switch 62 is considered a machine constant reference signal for purposes of comparison to other signals hereafter described. The machine constant reference signal from proximity switch 62 is transmitted to a main control system for further processing as described hereafter.

[0062] The distinct and separate absorbent pads 32 formed by separating device 48 are positioned upon the continuously moving first layer of material 54 provided by supply device 52. It is well known in the art to separate and position individually cut absorbent pads onto a continuously moving layer, and any such suitable mechanism can be utilized herein.

[0063] A supply device 64, which can be a standard unwind similar to that used with reference to the supply device 52, provides a continuously moving second layer 66 of material that will subsequently be joined to continuously moving first layer 54. The continuously moving second layer 66 can be any material suitable for the finished product, and in this particular description is a liquid impermeable film that will subsequently form liquid impermeable outer cover 34 (FIG. 1). One desired suitable liquid impermeable film is a 0. 75 mil polyethylene film commercially available from Pliant Corporation of Schaumburg, Ill., U.S.A. A continuously moving second layer 66 is moved toward a pair of rolls comprising a drive roll 68 and a support roll 70 that form there between a feed nip 72. The material of which second layer 66 is made is desirably microcrepable, in that it can be gathered, by way of example only, between about 0 millimeters to about 50 millimeters. Other materials having greater microcreping can be utilized as the material or materials for second layer 66.

[0064] In certain embodiments of this invention, due to variability of suppliers, at times drive roll 68 may run faster than a third layer 92 and no microcreping may occur. In fact, layer 66 may be stretched in this situation. Desirably, the second layer 66 is pliable to be able to gather into pleats or crepes. Suitable materials include, but are not limited to, a polyethylene film, a polypropylene film, a nonwoven material, a woven material or any suitable layer that is easily gatherable. It may also be desirable to have the ability to slightly stretch the material, particularly, for momentary retard moves, described hereafter.

[0065] It is important that the feed nip motor 148 (FIG. 6) and its drive system, which operates drive roll 68, is one that is capable of performing two types of speed variations, as controlled by the main control system, which will be described in greater detail hereafter. One speed variation is to increase a present speed of the rotation to a faster speed of rotation, or to decrease a present speed of rotation to a slower speed of rotation. The other speed variation is a momentary speed variation comprising an incremental advance phase move, which is a momentary speed increase of drive roll 68 to provide a measured increased amount of the layer of material, or an incremental retard phase move, which is a momentary speed decrease of drive roll 68 to provide a measured decreased amount of the layer of material. The term “momentary speed increase” refers to increasing a first speed to a higher second speed for a selected period of time, and then causing or allowing the speed to return to the first speed. The term “momentary speed decrease” refers to decreasing a first speed to a lower second speed for a selected period of time, and then causing or allowing the speed to return to the first speed.

[0066] As described earlier, the present invention can be utilized to register two continuously moving layers together, so that a reference mark and/or product component of one layer is registered with a reference mark and/or product component on the second layer. In this particular description, a component, such as a registered graphic 38 (FIG. 1) on continuously moving second layer 66 (FIG. 5A) is brought in registration with a component, such as an absorbent pad 32, on continuously moving first layer 54. By controllably registering a registered graphic 38 with an absorbent pad 32, the desired position of registered graphic 38 on a front panel 12 (FIG. 1) of a training pant 10 can be accomplished. An important function of a registered graphic 38 on a front panel 12 is that it visually informs the user of the proper orientation of the training pant 10 for donning purposes, thereby permitting the training pant to properly function, i.e., absorb waste, among other functions. The continuously moving second layer 66 has, by way of example, preprinted thereon a plurality of separate and distinct graphics 38, understanding again that a graphic 38 can be any desired design or pattern, such that the graphics 38 can be registered with the separate and distinct absorbent pads 32 on continuously moving first layer 54. There is associated with each graphic 38 a preprinted reference mark 74, which in this case is an optical brightener. The graphics 38 and their respective reference marks 74 can be provided on second layer 66 in any suitable manner well known in the art.

[0067] With reference to FIG. 3, there is illustrated a portion of continuously moving second layer 66 having a plurality of the graphics 38 and reference marks 74 preprinted or prepositioned thereon. Associated with each graphic 38 is a printed waistband 76 with a printed front edge 78 and a printed back edge 80. Similarly, each reference mark 74 has a reference front edge 82 and a reference back edge 84. Each reference mark 74 will be used to properly position an associated graphic 38 with an absorbent pad 32. The reference marks 74 are positioned off graphics 38, but could be printed directly on the graphics 38 so as to be within the design of the graphics. Further, the reference marks 74 can be eliminated, and a portion of a graphic 38 can be used as the reference mark. For example, a detectable mark or the like could be printed as part of the waistband 76 and thereafter used for properly registering the graphic 38. However, for purposes of explanation and manufacture, reference marks 74 are provided a selected distance apart from respective graphics 38.

[0068] Referring again to FIG. 5A, the continuously moving second layer 66 is moved toward a microcreping device 75 positioned with respect to a vacuum conveyor 188. The microcreping device 75 creates microcrepes as a result of transferring or conveying the second layer 66 from the drive roll 68 to the vacuum conveyor 188, traveling at a slower rate of speed than drive roll 68. Desirably, but not necessarily, the drive roll 68 can have vacuum on an outer surface to hold layer 66 on the outer surface or drive roll 68 before releasing the material to vacuum conveyor 188. Other suitable means may be used to maintain contact between the second layer 66 and the drive roll 68, such as friction and/or electrostatic means. The second layer 66 is removed from drive roll 68 and transferred or conveyed to vacuum conveyor 188 using suitable transferring means. For example, the vacuum may be shut off, a timed internal blast can be engaged or a relatively higher vacuum can be applied by the vacuum conveyor 188 to remove layer 66 from drive roll 68 and onto vacuum conveyor 188 to microcrepe the second layer 66. This microcreping process shortens layer 66. At times when material variability occurs, layer 66 may have no microcreping. This happens when the repeat length on layer 66 is equal to or less than the machine product length. In fact, second layer 66 can be stretched during a large retard phase move, described hereafter. Drive roll 68 can be driven by any suitable motor 148, as shown in FIG. 6, such as those described in the U.S. patents incorporated herein by reference. A suitable feed nip motor is a HR 2000 brushless AC servo motor available from Reliance Electric Company of Cleveland, Ohio, U.S.A.

[0069] As shown in FIG. 5A, in one embodiment of this invention, the second layer 66 is conveyed or moved toward the microcreping device 75 positioned between unwind 64 and laminating area 90. In one embodiment of this invention, the microcreping device 75 may include a vacuum 177 positioned with respect to the second layer 66 to maintain the second layer 66 in contact with a surface of a vacuum conveyor belt 73. As shown in FIG. 5A, vacuum 177 is operatively connected to vacuum source 175. Any suitable vacuum known to those having ordinary skill in the art may be used to maintain the second layer 66 in contact with the vacuum conveyor belt 73. Alternatively, or in addition, to the vacuum 177, the vacuum conveyor belt 73 may have a sufficient coefficient of friction to maintain the second layer 66 in contact the surface of the vacuum conveyor belt 73.

[0070] Desirably, the vacuum conveyor belt 73 moves or travels at a different speed, for example a slower speed, than the drive roll 68 and the support roll 70. As a result, as the second layer 66 is placed on the relatively slower moving conveyor belt 73, the second layer 66 is microcreped. As the second layer 66 moves along conveyor belt 73, a distance between successive reference marks 74 corresponding to the length of the second layer 66 decreases from the initial repeating length to the final repeating length corresponding to the machine product repeating length due to the microcreping process.

[0071] In the following description, the continuously moving second layer 66 will be described, by way of example, as being joined or laminated to another third layer 92 (FIGS. 5A and 5B) of material in order to produce a two-layered laminate 93 that ultimately will form the liquid impermeable outer cover 34 (FIG. 1). The polyethylene film material of which layer 66 is made serves as a liquid impermeable barrier, while the third layer of material 92 joined to layer 66 will provide cloth-like texture to the outer cover. The cloth-like layer will be the outermost layer. There is no requirement, however, for the third layer 92, and in some product designs, the cloth-like layer can be eliminated. Similarly, the film layer can be eliminated, and the cloth-like layer only can be used. The materials for second layer 66 and third layer 92 can be switched in alternate configurations.

[0072] The second layer 66 is driven or moved toward a laminator chill roll 86 and an associated support roll 88, comprising the laminating area 90. A continuously moving third layer 92 is provided in any suitable manner, and driven in any suitable manner to laminator chill roll 86. For example, as shown in FIG. 5A, the third layer 92 is supplied from a supply device 137 and moves toward chill roll 86. The supply device 137 can be any standard unwind device, such as a similar device to the supply device 64. The continuously moving third layer 92 can be any material suitable for the finished product, and in this particular description is a nonwoven web, such as a spunbond polypropylene web having a basis weight of about 20 grams per square meter (gsm), that will subsequently form part of the outer cover 34 (FIG. 1).

[0073] An adhesive applicator 94 applies a desired pattern of a suitable adhesive to the continuously moving third layer 92. The adhesive applicator 94 can be any suitable applicator well known in the art that can provide or apply the desired pattern of adhesive. The adhesive used can be any suitable adhesive that is compatible with layers 66 and 92, in order to ensure their proper lamination together. This ensures that the microcrepes 166, as shown in FIG. 5A, are maintained when the second layer 66 is laminated to third layer 92. The third layer 92 supports the microcrepes as the composite layer proceeds through the apparatus.

[0074] Laminator chill roll 86 is driven by the lineshaft 128 (FIG. 6) and assists in moving the layers in the process. The laminator chill roll 86 also serves to cool the adhesive applied by adhesive applicator 94 for processing purposes, thereby preventing adhesives from bleeding through the layers 66 or 92.

[0075] Once layers 66, 92 are laminated and pass through the laminating area 90, they are continuously moved to a construction chill roll 96, and have an adhesive applied to the outermost surface of layer 66. Construction chill roll 96 is lineshaft driven by lineshaft 128, similar to chill roll 86. The adhesive applied by adhesive applicator 98 will ultimately join layers 66, 92 to continuously moving first layer 54. Thus, the adhesive applicator 98 is selected to apply the appropriate adhesive pattern and amount of adhesive to ensure the desired joining of the layers 66, 92, and 54. The construction adhesive applicator 98 can be any type of applicator suitable for the desired adhesive pattern, and appropriate and compatible for the materials to be joined.

[0076] From construction chill roll 96, the laminated layers 66, 92 are then superimposed over continuously moving layer 54, and together the layers pass through a product tacker 100 comprising a drive roll 102 driven by lineshaft 128 (FIG. 6) and a rubber-coated idler roll 104. Tacker 100 compresses the layers together in order to cause the applied adhesive to join layers 66, 92 to continuously moving layer 54, thereby forming a continuously moving composite laminate 93, as shown in FIG. 4.

[0077] Continuing to refer to FIG. 5A, a first sensing means, such as a sensor 106, is suitably positioned between drive roll 68 and laminator chill roll 86 and with respect to conveyor 188 for detecting and generating a signal in response to each reference mark 74. Drive roll 68 can be a vacuum roll, a friction roll or a smooth roll that at times runs faster than vacuum conveyor 188 and creates the microcrepes 166. Since the reference marks 74 are ultraviolet-sensitive optical brighteners, a suitable sensor is a SICK detector model LUT 2-6 available from SICK OPTIK ELEKTRONIK, Inc., having a business office in St. Paul, Minn., U.S.A.

[0078] Positioned downstream of product tacker 100 are a second and third sensing means, such as a sensor 108 and a photoeye 110. The term “downstream” refers to a left-to-right direction as viewed in FIGS. 5A and 5B, and is also the machine direction for the process. Parenthetically, although layers 66 and 92 are illustrated as moving in a downwardly direction, the primary direction in which they are moving or will eventually move is in a left-to-right direction, and is also thus termed the downstream direction. Sensor 108 can be the same type of ultraviolet detector as sensor 106. The photoeye 110 is desirably a Banner RSBF scanner block, RPBT wiring base, IR 2.53S fiber-optic pair device, available from Banner Engineering, Corp. of Minneapolis, Minn., U.S.A. Photoeye 110 is designed to optically detect a product component, such as absorbent pad 32, and to generate an electrical signal in response thereto. In this particular description, both sensors 106 and 108 are designed to detect and generate a signal in response to a reference mark 74, and photoeye 110 is designed to detect and generate a signal in response to an absorbent pad 32. If desired, photoeye 110 can sense other components, such as waist elastics, leg elastics, fastening tapes utilized in diapers, or the like. A reference mark also can be associated with each absorbent pad 32 in the same manner that a reference mark 74 is associated with a graphic 38; and in that case, the photoeye 110 can be replaced with a sensor similar to sensors 106, 108. Similarly, sensors 106, 108 can be replaced with other sensors, similar to photoeye 110, in order to optically detect a product component or other structure in order to generate an appropriate signal.

[0079] In one embodiment of this invention, as shown in FIG. 5B, a microcreping device 172 comprises a support roll 170 desirably, but not necessarily, operatively connected to microcreping drive roll 168 to form a nip there between. Drive roll 168 travels at a speed greater than the third layer 92. The surface on drive roll 168 can receive vacuum from source 175 that is timed to carry the overfeeding material 66 into layer 92 where the adhesive on layer 92 from the adhesive applicator 94 adheres the microcreped second layer 66 to third layer 92. The microcrepes are created as a result of the difference in speed at which second layer 66 travels or moves compared to the speed at which the third layer 92 travels or moves. The drive roll 168 may comprise a means for supplying a timed air blast to assist in the transfer. Additionally, a vacuum conveyor (not shown) may be positioned with respect to third layer 92 to assist in the transfer and the microcreping or micropleating process. The end result of this process is the ability to consistently overfeed layer 66 onto layer 92 without having any wrap-ups due to an uncontrolled slack web. The two processes as described herein with reference to FIGS. 5A and 5B may be combined, if desired, to perform the microcreping process.

[0080] As shown in FIGS. 5A and 5B, a continuously moving composite laminate 93 comprises layers 66, 92, and 54 after they have been joined together by product tacker 100. Each printed waistband 76 will ultimately be cut along a respective cut line 120 in order to form individual products. In FIG. 4, once cut lines 120 have been separated, a front waist edge 116 and a back waist edge 118 are formed for each assembled product. Each absorbent pad 32 includes a front edge 112 and a back edge 114. One of the important features in FIG. 4 is the relative placement of a graphic 38 with respect to each product that will eventually be formed. Each graphic 38 is located in the front panel 12 (FIG. 1) and is located in the same position relative to an absorbent pad front edge 112 (FIG. 4). Naturally, other marks or product components can be in registration with other different reference marks or product components. For example, a simulated waist ruffle 29 (FIG. 2) can be registered relative to a waist opening, or leg elastics, such as leg elastics 30 (FIG. 1), can be desirably registered in relation to an absorbent pad, such as absorbent pad 32 (FIG. 4).

[0081] Referring to FIG. 6, there is schematically illustrated a main control system with the mechanical side 122. The main control system comprises a main registration control system 124 that receives various generated signals, processes them in accordance with programmed instructions, and generates output signals to a main drive control system 126. The main drive control system 126 receives the signals from the main registration control system 124, and in response thereto operatively adjusts microcreping device 75 and drive roll 68 (FIG. 5A).

[0082] Mechanical side 122 comprises a lineshaft 128 that directly drives selected mechanisms or, through a system of gears and other coupling devices, both electrical and mechanical, indirectly drives other components. Specifically, a feed nip and microcreping device gearing encoder 130 and a lineshaft registration encoder 132 are operatively coupled to lineshaft 128. Examples of encoder include an H25D-SS-2500-ABZC-8830-LED-SM18 (which can be used as encoder 130), available from BEI Motor System, Co. of Carlsbad, Calif., U.S.A., and a 63-P-MEF-1000-T-0-00 (which can be encoder 132) available from Dynapar Corp. of Gurnee, Ill., U.S.A.

[0083] The main registration control system 124 comprises hardware and/or preprogrammed software instructions, and can be represented, with reference to FIG. 6, as comprising an input acquisition system 134, a gear ratio control 136, a relative position 138, an automatic set point generation 140, a difference block 142, and a placement control 144. The main registration control system 124 includes a computer, which can comprise, for example, a VME-based microprocessor, such as a SYS68K/CPU-40B/4-01 available from Force Computers, Inc. of Campbell, Calif., U.S.A.

[0084] As illustrated in FIG. 6, input acquisition system 134 receives the following six generated signals: (i) a signal from a motor encoder 146 operatively coupled to the microcreping device feed motor 148, (ii) a signal from sensor 106 (FIGS. 5A and 5B), (iii) a signal from proximity switch 62, (iv) a signal from lineshaft registration encoder 132, (v) a signal from sensor 108, and (vi) a signal from photoeye 110. Input acquisition system 134 receives and counts the pulses generated by motor encoder 146 and lineshaft registration encoder 132, and receives signals from sensors 106, 108, proximity switch 62, and photoeye 110. Referencing the accumulated counts of encoder 146 and the accumulated counts of encoder 132, input acquisition system 134 performs preprogrammed instructions that are specific to the respective received signals, and stores the results of the instructions.

[0085] Desirably, the microcreping device feed roll motor 148 and its drive system, which operates drive roll 68, is capable of performing two types of speed variations, as controlled by the main control system, described above. One speed variation is to increase a present speed of the rotation to a faster speed of rotation, or to decrease a present speed of rotation to a slower speed of rotation. The other speed variation is a momentary speed variation comprising an incremental advance phase move, which is a momentary speed increase of drive roll 68 to provide a measured increased amount of the layer of material, or an incremental retard phase move, which is a momentary speed decrease of drive roll 68 to provide a measured decreased amount of the layer of material. While making an advance phase move, layer 66 will be shortened by momentarily speeding up feed roll 68 to increase the microcreping process, i. e. create more microcrepes. While making a retard phase move, layer 66 will be lengthened by momentarily slowing down feed roll 68 to decrease the microcreping process, i. e. reduce the amount of microcrepes created. In large retard moves, layer 66 may even be stretched and no microcreping may occur.

[0086] The input acquisition system 134 performs the following functions for the gear ratio control 136. A signal counter in input acquisition system 134 counts the pulses from motor encoder 146, and receives signals from sensor 106 in response to each reference mark 74 (FIGS. 5A and 5B). The input acquisition system 134 then measures the counted pulses representing a distance between every two successive reference marks 74, and performs a running average of those measured counts. The term “running average” refers to averaging the same number of data; for example, for each newly received datum input, the latest, i. e. the oldest, datum is removed from the averaging calculation. The averaging of the counts between two successive reference marks 74 creates an average measurement upon which the next gear ratio value will be derived by gear ratio control 136, as opposed to basing a control decision on the measurement from just one pair of reference marks 74. This averaging “smoothes out” the measurements, and is necessitated due to the variability of the apparatus and process. The number of measurements to average is controllable, and is set or determined by providing an appropriate instruction via manual input in any suitable manner well known in the art. In conjunction with performing a running average of the measured counts, the input acquisition system 134 performs a filtering function, which is preprogrammed, to filter out signal anomalies. Examples of such signal anomalies include a dirty photoeye, missing or extra reference marks 74, movement or weaving of the layers, measuring the counts outside a preprogrammed range for averaging purposes, known inaccurate data due to registration control events, or the like.

[0087] The input acquisition system 134 performs the following functions for the relative position 138. The input acquisition system 134 counts the pulses received from lineshaft registration encoder 132, and receives signals generated by sensor 106 and proximity switch 62. Input acquisition system 134 then determines and records the current accumulated number of pulses upon receiving a signal from sensor 106, and determines and records the current accumulated number of pulses upon receiving a signal from proximity switch 62.

[0088] The input acquisition system 134 performs the following functions for the automatic set point generation 140. Input acquisition system 134 counts the pulses received from lineshaft registration encoder 132, and receives the signals generated by sensor 108 and photoeye 110. It then determines and records the current accumulated number of pulses upon receiving a signal from sensor 108, and determines and records the current accumulated number of pulses upon receiving a signal from photoeye 110. Thereafter, input acquisition system 134 calculates the difference between the current accumulated number of pulses from one signal of sensor 108 and the current accumulated number of pulses from an associated signal of photoeye 110; the “associated signal” refers to the signal generated by photoeye 110 (FIGS. 5A and 5B), with the signal from sensor 108, for each machine product repeat length. With these calculated differences, input acquisition system 134 performs a running average and standard deviation for those differences.

[0089] The various calculations and functions performed by input acquisition system 134 are utilized by other portions of main registration control system 124 in order to generate commands to main drive control system 126 (FIG. 6). Main drive control system 126 generally comprises a logic/control processor 150, an electronic gear box 152, and a motor controller 154. The main drive control system 126 includes a computer, which can comprise, for example, a Reliance Distributed Control System made by Reliance Electric, Co. The Distributed Control System includes a Reliance Electric Automax Processor and associated hardware. The electronic gear box 152 (FIGS. 6 and 7) comprises a 2-axis card that is part of the Distributed Control System unit and is used to control the position of motor 148.

[0090] Within main registration control system 124, the gear ratio control 136 queries the input acquisition system 134 every 20 products, i.e., every 20 machine product repeat lengths, for the current running average of measured counts representing a distance between successive reference marks 74 (FIGS. 5A and 5B), which is the repeat value. The number of product lengths determining a query from gear ratio control 136 is adjustable, and can be changed manually by the operator. After determining the repeat value, gear ratio control 136 performs a gear ratio calculation in accordance with preprogrammed instructions to determine a new gear ratio value. That new gear ratio value is then transmitted to the logic/control processor 150 of main drive control system 126. The gear ratio value is calculated by dividing the repeat value by the number of encoder counts from the feed nip gearing encoder 130 (FIG. 6) that occur in one machine product repeat length.

[0091] The relative position 138 of main registration control system 124 queries input acquisition system 134 for the current accumulated number of pulses relative to sensor 106, and the current accumulated number of pulses relative to proximity switch 62. Relative position 138 then determines the difference between the two current accumulated number of pulses in order to calculate a relative position of a reference mark 74 (FIGS. 5A and 5B) to the associated proximity switch signal for that specific query for each machine product repeat length. The relative position 138 then generates and transmits to difference block 142 a relative position value.

[0092] If no auto set point is used, the relative position is compared to a manually entered control value. Once every machine product repeat length, a difference block 142 determines the difference between the current control set point value (which in this case is the manually entered set point value) and the associated relative position value from the relative position 138, which is the placement error. The difference block 142 transmits this placement error, in lineshaft encoder counts, to placement control 144. The placement control 144 compares the placement error to a tolerance band 170 (FIG. 8), which defines an acceptable deviation of the relative position value about the current control set point. The tolerance band 170 remains constant about the control set point. As a result, the position control of the reference marks occurs at the microcreping device 75. The placement control 144 will not execute a placement correction if a previous placement correction has not been completed including a time delay for system reaction on layer 66 due to action of the microcreping device 75 in accordance with preprograrnmed instructions.

[0093] The automatic set point generation 140 queries the input acquisition system 134 for each machine product repeat length representing a single product. The occurrence of each product, or machine product repeat length, is determined from the lineshaft registration encoder 132, in which two revolutions of lineshaft registration encoder 132 is equivalent to one product length. In this particular example, two revolutions of lineshaft registration encoder 132 is 2,000 counts.

[0094] The input acquisition system 134 responds to each query from automatic set point generation 140 with the current running average and standard deviation of the difference calculated between the current accumulated number of pulses for one signal of sensor 108 and the current accumulated number of pulses from an associated signal from photoeye 110 for each product; the current running average of this calculation is the actual position value. The automatic set point generation 140 then compares a standard deviation with a preset limit, which has been manually entered, and if the standard deviation is outside the preset limit, the automatic set point generation 140 will ignore that datum and not determine a new set point since the standard deviation data is considered too variable to make an accurate set point adjustment. If the standard deviation is within the preset limit, the automatic set point generation 140 will then determine the difference between the actual position value and a manually entered target value, which is the desired actual position value. If the new calculated difference is determined, by automatic set point generation 140, to be within a prescribed range, no further action or calculation will be made. However, if the difference is outside the prescribed range, the automatic set point generation 140 will determine a new control set point. This new control set point is derived by adding to the current set point the difference between the target value and actual position value.

[0095] Referring now to FIG. 6, once every machine product repeat length, a difference block 142 determines the difference between the current control set point value from automatic set point generation 140 and the associated relative position value from relative position 138, which is the placement error. However, the system can function using a forced comparison number from an operator interface system to be the value for the automatic set point generation 140 and therefore does not use the actual measured values from sensors 108 and 110. In this case, the only time the control set point number would vary is when the operator would input a new number for the current control set point value. Continuing on if automatic set point is used, the difference block 142 transmits this placement error, in lineshaft encoder counts, to placement control 144. The placement control 144 compares the placement error to a tolerance band 170 (FIG. 8), which defines an acceptable deviation of the relative position value about the current control set point. The tolerance band 170 remains constant about the control set point, but the control set point can vary as calculated by automatic set point generation 140.

[0096] With reference to FIG. 8, there is illustrated one derived set point 168 having a prescribed tolerance band 170. For purposes of explanation, the control set point 168 has a value of 1,000 counts, and the tolerance band 170 represents a deviation of plus or minus 12 counts. Each of the datum points 172, 174, 176, 178, 180 and 182, represents one product's relative position value as calculated by relative position 138. Waveform 156 represents signals generated by proximity switch 62, and waveform 158 represents signals generated by sensor 106. If a placement error value remains within tolerance band 170, no placement command will be generated. However, if a placement error value is outside tolerance band 170, then placement control 144 will generate a placement command. The placement command is directly proportional to the size of the difference represented by the value from difference block 142. The generated placement command is then transmitted to the logic/control processor 150 of main drive control system 126. FIG. 8 illustrates an example of how placement control 144 (FIG. 6) compares each datum point 172-182 to a current control set point in order to generate a placement error. The placement error for each datum point is compared to tolerance band 170 to determine if a placement command should be generated. In the example, point 176 is the only datum point where the placement error falls outside the tolerance band 170, which causes a placement command to be generated, thereby causing a following datum point to fall within the tolerance band 170.

[0097] Upon receiving a gear ratio command or placement command signal from the main registration control system 124, the main drive control system 126 will use the received signals from the placement control 144 and gear ratio control 136 to regulate the speed of the motor 148 driving the microcreping device 75 (FIG. 5A). By decreasing the speed of the motor 148, the system will decrease the speed of the microcreping device roll 68 to reduce microcreping or to elongate layer 66 depending upon the magnitude of the speed change. If the speed of the motor 148 is increased, the system will increase the speed of layer 66 using the microcreping drive roll 68. Either the reduced or increased microcreping is done simultaneously with the repeat and/or placement moves being performed by drive motor 148 as commanded by motor controller 154. The operation of main drive control section 126 has been described in greater detail above.

[0098] The logic/control processor 150 (FIGS. 6 and 7) searches for and receives new commands from main registration control system 124. Specifically, processor 150 searches for and receives gear ratio commands from gear ratio control 136, and placement commands from placement control 144. For each gear ratio value update command, processor 150 transmits a command in accordance with preprogrammed instructions to electronic gear box 152 to modify the value used in a gear ratio block 208 (FIG. 7). For each placement command received from placement control 144, processor 150 transmits a placement command in accordance with preprogrammed instructions to electronic gear box 152.

[0099] Referring to FIG. 7, electronic gear box 152 is schematically illustrated as comprising a gear ratio block 208, a difference block 210, a speed regulator 212, and an incremental move block 214. The gear ratio block 208 receives a gear ratio value from logic/control processor 150 (FIG. 6), and receives a pulse train from the microcreping device feed gearing encoder 130. Gear ratio block 208 scales the pulse train from gearing encoder 130 and applies the gear ratio value to it in order to generate a reference signal to difference block 210. Difference block 210 receives both the reference signal from gear ratio block 208, and also receives a feed back signal from motor encoder 146, which communicates the current speed of motor 148. The difference block 210 determines the difference between the signals and generates a command signal to a speed regulator 212, which generates a speed reference signal to motor controller 154.

[0100] With reference to FIGS. 6 and 7, electronic gear box 152 also receives a placement value from logic/control processor 150, and this placement value is received by incremental move block 214. Incremental move block 214 performs a “one time” move to appropriately change the reference signal. In response to the placement command, an incremental move signal is generated and temporarily added to difference block 210, which increments or decrements, the reference signal received from gear ratio block 208, thereby resulting in a momentary change in the speed command signal sent to the speed regulator 212. Motor controller 154 receives the speed command signal from electronic gear box 152 (FIG. 6) and varies the speed of motor 148, which is represented by the motor encoder pulse train, in response thereto.

[0101] As described, in order to appropriately and desirably register graphic 38 (FIG. 1) or graphic 42 (FIG. 2) in respective training pants 10, 40, this is accomplished, with reference to FIGS. 5A and 5B, by selectively controlling the distance between successive reference marks 74 (FIGS. 5A and 5B), so that each mark 74 will be desirably registered with an associated component, such as an absorbent pad 32. By controlling the distance between reference marks 74 to a selected distance, such as machine product repeat length, variations or other types of anomalies inherently present in such an apparatus or process can be identified and controlled. Further, by adjusting the microcreping of continuously moving second layer 66, it can be appropriately registered with continuously moving first layer 54, thereby ensuring proper registration of a desired component, such as a graphic 38, to another component, such as an absorbent pad 32. As described therefore, reference marks 74 are controllably registered with respective absorbent pads 32 on continuously moving first layer 54.

[0102] While this invention has been described as having a preferred embodiment, it will be understood that it is capable of further modifications. It is therefore intended to cover any variations, equivalents, uses, or adaptations of the invention following the general principles thereof, and including such departures from the present disclosure as come or may come within known or customary practice in the art to which this invention pertains and fall within the limits of the appended claims. 

We claim:
 1. A process for controllably registering a continuously moving first layer with a continuously moving second layer, comprising the steps of: providing a continuously moving first layer having a repeating machine product length represented by a plurality of first repeating reference marks, wherein the first repeating reference marks are in registered relationship with a machine constant reference signal; providing a continuously moving second layer having a repeating initial length greater than the repeating machine product length, the repeating initial length represented by a plurality of second repeating reference marks; sensing each of the second reference marks and generating a reference mark signal in response thereto; measuring the distance between two successive second repeating reference mark signals and generating a repeat corrective control signal in accordance with programmed instructions; adjusting the distance between two successive second reference marks in response to a generated repeat corrective control signal and providing the continuously moving second layer having a repeating final length; sensing a second reference mark of the continuously moving second layer relative to a corresponding machine constant reference signal, and generating a placement corrective control signal in accordance with programmed instructions; adjusting the speed of the continuously moving second layer in response to a generated placement corrective control signal to controllably register a second reference mark on the continuously moving second layer with its corresponding first reference mark on the continuously moving first layer; micropleating the second layer; and superimposing the continuously moving first layer and the continuously moving second layer together.
 2. The process of claim 1 further comprising the steps of: laminating the continuously moving first layer to the continuously moving second layer; sensing the first repeating reference marks and the second repeating reference marks; comparing the first repeating reference marks and the second repeating reference marks relative to preprogrammed instructions; generating a control point; comparing the generated control point to a placement control set point; and changing the preprogrammed instructions to a new control point for placement corrective control when the placement control set point is different than the generated control point.
 3. The process of claim 1 wherein the step of generating a repeat corrective control signal includes generating a microcreping repeat corrective control signal.
 4. The process of claim 1 wherein the step of adjusting the distance between two successive second reference marks in response to the generated repeat corrective control signal includes microcreping the second layer.
 5. The process of claim 1 wherein the step of adjusting the distance between two successive second reference marks in response to a generated repeat corrective control signal includes moving the continuously moving second layer through a microcreping device.
 6. The process of claim 1 wherein the step of adjusting the distance between two successive second reference marks in response to a generated repeat corrective control signal includes moving the second layer through a registration roll.
 7. The process of claim 1 wherein the continuously moving second layer is moved along a vacuum conveyor belt having a different speed than a speed of a drive roll supplying the continuously moving second layer.
 8. The process of claim 7 wherein the vacuum conveyor belt has a slower speed than the speed of the drive roll.
 9. The process of claim 1 wherein the repeating final length of the second layer corresponds to the repeating machine product length.
 10. The process of claim 1 wherein a third layer of material is laminated to the second layer before superimposing the continuously moving first layer and the continuously moving second layer.
 11. The process of claim 10 wherein the second layer comprises a film.
 12. The process of claim 10 wherein the third layer comprises a nonwoven web.
 13. The process of claim 10 wherein the second layer and the third layer form a liquid impermeable outer cover.
 14. A process for controllably registering a continuously moving first layer with a continuously moving second layer, comprising the steps of: providing a continuously moving first layer having a repeating machine product length represented by a plurality of first repeating reference marks; providing a continuously moving second layer having a repeating initial length greater than the repeating machine product length, the repeating initial length represented by a plurality of second repeating reference marks; microcreping the continuously moving second layer; sensing each of the second reference marks and generating a reference mark signal in response thereto; measuring the distance between two successive reference mark signals and generating a repeat corrective control signal in accordance with programmed instructions; adjusting the speed of the continuously moving second layer in response to the generated repeat corrective control signal; sensing a marker pulse corresponding to a position of a first reference mark on the continuously moving first layer and a position of a second reference mark on the continuously moving second layer, and generating a placement corrective control signal in accordance with programmed instructions; registering a second reference mark on the continuously moving second layer with the marker pulse corresponding to a first reference mark on the continuously moving first layer; and superimposing the continuously moving first layer and the continuously moving second layer together.
 15. The process of claim 14 further comprising the steps of: laminating the continuously moving first layer to the continuously moving second layer; sensing the first repeating reference marks and the second repeating reference marks; comparing the first repeating reference marks and the second repeating reference marks relative to preprogrammed instructions, and generating a control point; comparing the generated control point to the placement corrective control signal; and changing the programmed instructions to a new control point for placement corrective control when the placement corrective control signal is different than the generated control point.
 16. The process of claim 14 wherein the step of generating a repeat corrective control signal includes generating a microcreping repeat corrective control signal.
 17. The process of claim 14 wherein the step of adjusting the distance between two successive second reference marks in response to the generated repeat corrective control signal includes microcreping the second layer.
 18. The process of claim 14 wherein the step of adjusting the distance between two successive second reference marks in response to a generated repeat corrective control signal includes moving the continuously moving second layer through a microcreping device.
 19. The process of claim 14 wherein the step of adjusting the distance between two successive second reference marks in response to a generated repeat corrective control signal includes moving the second layer through a registration roll.
 20. The process of claim 14 wherein a repeating final length of the second layer corresponds to the repeating machine product length of the first layer.
 21. The process of claim 14 wherein a third layer of material is laminated to the second layer to form a liquid impermeable outer cover before superimposing the continuously moving first layer and the continuously moving second layer.
 22. The process of claim 21 wherein the second layer comprises a film, a nonwoven web material, a composite structure, a coated nonwoven web material or an elastic assembly.
 23. The process of claim 21 wherein the third layer comprises a nonwoven web material, a composite structure or an absorbent assembly.
 24. A process for controllably registering a first continuous web having a first repeating length with a second continuous web having a second initial repeating length greater than the first repeating length, the method comprising the steps of: transporting the first continuous web toward the second continuous web; microcreping the second continuous web; and mating the first continuous web with the second continuous web, wherein the second continuous web has a final repeating length equal to the first repeating length.
 25. A process for controllably registering a first continuous web with a second continuous web, the method comprising the steps of: transporting the first continuous web defining a repeating machine product length toward the second continuous web having an initial repeating length, the initial repeating length greater than the repeating machine product length; microcreping the second continuous web to a final repeating length equal to the repeating machine product length to register the first continuous web with the second continuous web; and mating the first continuous web with the second continuous web. 